Casing structures for electronic devices

ABSTRACT

An aspect provides a method, including: fixing a laminated panel, which has been cut into a predetermined shape, to a mold, said laminated panel having an expanded layer disposed between layers made of a conductive resin; injection of molding non-conducting resin into the mold in which the laminated panel has been fixed; wherein a non-conductive region and a conductive region are joined to form a bottom surface of a display casing, said display casing having an inner and outer surface; and wherein an antenna mounting space is formed in the non-conductive region. Other aspects are described and claimed.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional application of the U.S. patent application Ser. No. 12/351,586, filed Jan. 9, 2009, which claims priority from Japanese Patent Application No. 2008-004213, filed on Jan. 11, 2008, both of which are hereby incorporated by reference as if fully set forth herein.

FIELD OF THE INVENTION

The present invention generally relates to a casing structure for an electronic apparatus.

BACKGROUND OF THE INVENTION

In recent years, a portable computer such as a notebook type personal computer (hereinafter, referred to as “notebook PC”) has been standardized to have a radio communication antenna. The radio communication antenna is disposed on an upper surface or a side surface of a liquid crystal display so that the antenna exhibits the optimum sensitivity when users use the notebook PC. In order to cope with recent demands such as broad and multiple frequency bands, a high data transfer rate, or a diversity communication, the number of antennas mounted on a display-side casing of the notebook PC has been more and more increased.

Japanese Patent Application Laid-Open No. 2005-149463 discloses an electronic apparatus casing in which a resin member for covering a distal end part of a base member containing a fiber is bonded to the base member by means of adhesive while preventing the adhesive from running over a joint surface of the resin member and the base member, thus covering a hangnail of the fiber at the distal end part. Japanese Patent Application Laid-Open No. 11-298158 discloses an electronic apparatus casing configured by a metal plate and wall parts formed of a composite heat-curable resin material, for coping with multiple purposes of, such as, a light weight, an electromagnetic shielding property, or a transformation. The metal plate and the wall parts are joined with each other in corrugated joint surfaces.

With further progress in the trend toward thinner size and lighter weight notebook PCs, the structure of the display casing has been further evolved to cope with such progress. In a metallic display casing, the cutout portions for securing the antenna sensitivity have weak points in terms of strength while posing designing problems; hence, a display casing having a new structure is demanded. Therefore, a need has been recognized for an electronic apparatus, especially, such as a next-generation notebook PC, to have a display casing capable of achieving a thin size and light weight.

BRIEF SUMMARY

The present invention generally relates to a casing structure for an electronic apparatus capable of accommodating a display module, the casing structure comprising a sidewall and a bottom surface in which a conductive resin region and a nonconductive resin region are butt joined.

In summary, one aspect of the present invention provides a method comprising: fixing a laminated panel, which has been cut into a predetermined shape, to a mold, said laminated panel having an expanded layer disposed between layers made of carbon fiber reinforced plastic; and injection molding glass fiber reinforced plastic into the mold in which the laminated panel has been fixed; wherein a glass fiber reinforced plastic region and a carbon fiber reinforced plastic region are butt joined to form a bottom surface of a display casing; and wherein an antenna mounting space is formed in the glass fiber reinforced plastic region.

Another aspect provides a method, comprising: fixing a laminated panel, which has been cut into a predetermined shape, to a mold, said laminated panel having an expanded layer disposed between layers made of a conductive resin; injection of molding non-conducting resin into the mold in which the laminated panel has been fixed; wherein a non-conductive region and a conductive region are joined to form a bottom surface of a display casing, said display casing having an inner and outer surface; and wherein an antenna mounting space is formed in the non-conductive region.

For a better understanding of the present invention, together and with other and further features and advantages thereof, reference is made to the following description, taken in conjunction with the accompanying drawings, and the scope of the invention will be pointed out in the appended claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective view illustrating an outer appearance of a notebook PC 10 according to an embodiment of the present invention.

FIG. 2 is a top plan view illustrating an inner surface of a display casing in which an LCD module is accommodated.

FIG. 3 is a top plan view illustrating a state where antennas are disposed in the display casing.

FIG. 4 is a top plan view illustrating a state where the LCD module is accommodated in the display casing.

FIGS. 5 (A-C) are a top plan view and cross-sectional views illustrating a detailed structure of a joint portion.

FIG. 6 is a perspective view for explaining a display casing and an LCD module.

DETAILED DESCRIPTION

It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, may be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the presently preferred embodiments of the present invention, as represented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention.

Reference throughout this specification to “one embodiment” or “an embodiment” (or the like) means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment.

Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are given to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

The illustrated embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals or other labels throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices that are consistent with the invention as claimed herein. The detailed description of the invention will briefly review some conventional arrangements and problems associated therewith in order to highlight some features of the instant invention (providing solutions to these problems). The description will then proceed with a more detailed description of preferred embodiments according to the present invention.

Referring now to the figures, the instant invention will be described with reference to the figures herein and the scope of the invention will be pointed out in the pending claims.

FIG. 6 is a schematic perspective view illustrating a structure of a display portion 213 of a conventional notebook PC. The display portion 213 includes a display casing 223, a display module 225, antenna mounting portions 227 a and 227 b, and a bezel 231. A variety of types of radio communication antennas are mounted on the antenna mounting portions 227 a and 227 b. The display casing 223 has a box-like structure, and the display module 225 is fixedly accommodated therein. The antenna mounting portions 227 a and 227 b are disposed between a side portion of the display module 225 and an inner surface of the display casing 223. The bezel 231 is disposed on a front surface of the display module 225 to be mounted on the display casing 223.

The display casing 223 is a structure for protecting internal components of, for example, the display module 225 from an external pressing force. For this reason, the display casing 223 has usually been formed of a thick glass fiber reinforced plastic, but nowadays, in order to achieve a thin size and a light weight while maintaining strength of the casing, light metals such as aluminum alloys or magnesium alloys are often used.

When antennas mounted on the antenna mounting portions 227 a and 227 b are disposed inside the display casing 223 formed of a conductive material such as metal, the sensitivity may be lowered. For this reason, in the case of the display casing 223 formed of metal, a structure is typically used in which cutouts 233 a and 233 b are formed in parts of a side portion thereof corresponding to the antennas, and caps 235 a and 235 b configured by nonconductive members such as rubber or plastics are packed into the cutouts 233 a and 233 b.

However, when the cutouts 233 a and 233 b are formed in the display casing 223, the strength at these portions is inevitably lowered undesirably. For this reason, it is necessary to decide the structure of the display casing 223 with the presumption that the strength will be lowered by the cutouts 233 a and 233 b so that sufficient strength can be ensured. Particularly, when a plurality of antennas is mounted on one casing, the cutouts are required by the number of antennas mounted, so that it leads to a limit in achieving a thin size and lightweight in a metallic casing.

Furthermore, according to co-pending and commonly assigned Japanese Patent Application No. 2007-069947, a display casing is configured by a composite member including a decorative cover formed of a nonconductive material for contributing to designing function and a frame formed of metal for contributing to strengthening function. However, such a casing still poses problems in the form of increased number of members used or the weight thereof because of the metal used therein.

Therefore, according to at least one presently preferred embodiment of the present invention there is broadly contemplated herein a casing structure for an electronic apparatus, which achieves a thin size and a lightweight. The casing structure for an electronic apparatus is capable of accommodating a display module, the casing structure comprises a sidewall and a bottom surface in which a conductive resin region and a nonconductive resin region are butt joined. The joining portions for the butt joining depict a curved line in the bottom surface of the casing. The joint portions allow respective end portions of two regions to contact with each other while depicting a curved line so that the size of contacting areas can be increased more than contacting them in a straight line, thus reinforcing the joint portions. Moreover, it is possible to secure a space in the thickness direction of the casing by means of the butt joining, thus achieving a thin size.

The curved line may be configured to include a regular corrugated line. In such a case, a pitch of the conductive resin region may be made to be the same as a pitch of the nonconductive resin region. The conductive resin region may be configured to contain a carbon fiber reinforced plastic. In such a case, when the conductive resin region is formed by a laminated panel having an expanded layer between layers made of carbon fiber reinforced plastic, it is possible to obtain a conductive resin region having a light weight and high strength. Moreover, when the casing structure is formed by fixing the laminated panel cut into a predetermined shape to a metallic mold and then flowing the molten glass fiber reinforced plastic into the metallic mold, the molten glass fiber reinforced plastic may come into the expanded layer of the butt joint portions, so that it is possible to increase the strength of the joint portions.

When the sidewall and a peripheral portion of the bottom surface are formed of the nonconductive resin so that an antenna mounting space is provided in a space defined by the sidewall and the bottom surface, radio waves can be transmitted and received through the bottom surface and the sidewalls, so that it is possible to improve the antenna sensitivity. When the thickness of the antenna mounting space is made to be smaller than the thickness of the joint portions and the conductive resin region, a larger space can be provided to an antenna, so that it is possible to increase the degree of freedom in antenna design. Since the butt joint portions do not form a corrugated surface in the bottom surface even when they are in the projection area of the display module, it is possible to obtain a casing structure having a thin size

FIG. 1 is a perspective view according to at least one embodiment of the present invention illustrating an outer appearance of a notebook PC 10. The notebook PC 10 has a liquid crystal display (LCD) module 15 accommodated in a display casing 13. A system casing 11 accommodates system devices such as a processor, a motherboard, a wireless module and a hard disk drive. A keyboard assembly 17 and a keyboard bezel 19 are mounted on an upper surface of the system casing 11. The system casing 11 and the display casing 13 are openably coupled to each other via hinge portions 21 a and 21 b.

FIG. 2 is a top plan view according to at least one embodiment of the present invention illustrating an inside of the display casing 13 in which the LCD module 15 is accommodated. The hinge portions 21 a and 21 b are positioned on the upper side of FIG. 2. The display casing 13 has strengthening function of accommodating the LCD module 15 and protecting the display module 15 from an external pressing force and also has designing function that an outer surface thereof constitutes an outer appearance of the notebook PC 10. Therefore, on a display side, there is no need to have a special frame member for securing strength in addition to the display casing 13.

The display casing 13 is formed by two regions: a glass fiber reinforced plastic (hereinafter, referred to as “GFRP”) region 101 formed of a nonconductive material and a carbon fiber reinforced plastic (hereinafter, referred to as “CFRP”) region 103 formed of a conductive material. The GFRP region 101 is disposed in a peripheral portion of the display casing 13 and constitutes sidewalls 13 a for forming the inside into a box-like shape. In the GFRP region 101, antenna regions 101 a and 101 b, an indicator region 101 c, and the other regions 101 d and 101 e are representatively depicted. The CFRP region 103 is disposed in the central part of the display casing 13 so as to occupy the whole area. The GFRP and the CFRP are both based on nylon.

The antenna regions 101 a and 101 b and the indicator region 101 c are configured to extend toward the central part from the sidewalls 13 a so that their boundaries 201 a to 201 c with the CFRP region 103 are formed into a regular waveform. The antenna regions 101 a and 101 b are used as spaces for mounting an antenna of, for example, a LAN or a WAN. The indicator region 101 c is used as a space for mounting a light emitting diode as an indicator. Moreover, the CFRP region 103 includes a camera region 103 a for mounting a camera.

FIG. 3 is a top plan view according to at least one embodiment of the present invention illustrating a state where antennas 251 a and 251 b are arranged in the display casing 13. The antennas 251 a and 251 b are configured by radiation element portions 255 a and 255 b and ground sheets 253 a and 253 b, respectively. The antennas 251 a and 251 b are connected to a wireless module accommodated in the system casing 11. In the radiation element portions 255 a and 255 b, a plurality of radiation elements corresponding to respective frequency bands is attached to the frame formed of synthetic resin. The ground sheets 253 a and 253 b are formed of an aluminum foil. The antennas 251 a and 251 b are disposed to be positioned on the upper side when the display casing 13 is opened as shown in FIG. 1, in order to improve the antenna's radio wave sensitivity.

FIG. 4 is a top plan view according to at least one embodiment of the present invention illustrating a state where the LCD module 15 is accommodated in the display casing 13. As is clear from FIGS. 3 and 4, the antenna regions 101 a and 101 b are configured to extend a sufficient distance toward the central part from the sidewalls 13 a so that the whole body of each antenna 251 a and 251 b can be mounted thereon. As a result, joint portions of the antenna regions 101 a and 101 b and the CFRP region 103 are in a projection area of the LCD module 15 with respect to the bottom surface. Since the whole body of each antenna 251 a and 251 b can be arranged within the antenna regions 101 a and 101 b formed of a nonconductive material, it is possible to obtain a good radio wave characteristic. Specifically, the antennas 251 a and 251 b are arranged such that the radiation element portions 255 a and 255 b are disposed between inner surfaces of the sidewalls 13 a of the display casing 13 and the LCD module 15, and most parts of the ground sheets 253 a and 253 b are disposed between the LCD module 15 and the antenna regions 101 a and 101 b.

Here, a description of a joint structure between the GFRP region 101 and the CFRP region 103 will be described. The GFRP region 101 and the CFRP region 103 need to form a single body to secure strength of the display casing 13 such as by holding the LCD module 15 or enduring an external pressing force. Therefore, the joint portions require a predetermined strength. As illustrated in FIG. 2, the joint portions of the GFRP region 101 and the CFRP region 103 include butt joint portions 201 a to 201 c depicting regular waveforms in the bottom surface and lap joint portions 201 d and 201 e shown by straight lines. The lap joint portions 201 d and 201 e are only illustrations, and all joint portions of the GFRP region 101 and the CFRP region 103 other than the butt joint portions 201 a to 201 c are lap joined, that is, in an overlapping manner.

In the lap joint portions 201 d and 201 e, the GFRP region 101 is lap joined over the CFRP region 103 so that it bulges toward the inner side of the display casing 13. In the butt joint portions 201 a to 201 c, an end portion of the GFRP region 101 and an end portion of the CFRP region 103 are butt joined at contacting surfaces depicting regular corrugated curves such as waveforms in the bottom surface. Although the lap joining can provide higher strength than the butt joining, the lap joining is applied only to areas disposed outside the projection area of the LCD module 15 with respect to the bottom surface because the lap joint portions become thicker at the inner side. Alternatively, a method of the lap joining such that the GFRP region 101 bulges toward the outer side of the display casing 13 at the lap joint portions may be considered; however, such a method may not be applied because of designing problems.

In accordance with at least one presently preferred embodiment of the invention, the thickness of the CFRP region 103 is about 1.5 mm and the thickness of the antenna region 101 a is about 1 mm to 1.5 mm. The CFRP region 103 is produced by cutting a laminated panel having an expanded layer sandwiched between two CFRP layers into the shape of the CFRP region 103 as shown in FIG. 2. By applying such a laminated panel to the central portion where it is necessary to increase the strength of the display casing 13, it is possible to produce the display casing 13 as being lightweight and having increased strength. Then, the display casing 13 is formed by injection molding in which the processed CFRP panel 103 is set on a metallic mold and a GFRP heated to be melt is press-fitted to the metallic mold.

FIG. 5A is a top plan view according to at least one embodiment of the present invention illustrating a detailed structure of the antenna region 101 a and the joint portion 201 a. FIG. 5B is a cross-sectional view according to at least one embodiment taken along the arrows A-A in FIG. 5A, and FIG. 5C is an enlarged cross-sectional view according to at least one embodiment of the joint portion 201 a. In FIG. 5B, a thickness t1 of a principal surface constituting the antenna region 101 a is set to 1 mm; however, a thickness t2 thereof in the vicinity of a joint surface with the CFRP region 103 is set to 1.5 mm, which thickness is the same as the thickness of the CFRP region 103.

The antenna regions 101 a and 101 b are coupled with the camera region 103 a by means of butt joining, so that it is possible to secure sufficient strength. Since the radiation element portion 255 a of the antenna 251 a can be arranged in a thin (thickness t1) part of the antenna region 101 a, a space for the radiation element portion 255 a of the antenna 251 a can be provided in the thickness direction of the display casing 13, easing restrictions on an antenna design and thus obtaining a good antenna characteristic. Further, by allowing the antenna regions 101 a and 101 b to be thin, it is possible to achieve a light weight of the display casing 13.

In the joint portion 201 a, an end portion of the antenna region 101 a and an end portion of the CFRP region 103 are contacted each other in a curved surface depicting a regular corrugated line and having a width L1 of about 6 mm and a length L2 of about 7 mm as viewed in top plan view. The contacting surface may have other shapes as long as it can increase the size of contacting areas of two materials to thus increase the coupling strength. Since the CFRP region 103 has a laminated structure having the expanded layer 109 inserted between the CFRP layers 105 and 107, the GFRP melt in the process of the injection molding can partially come into the expanded layer 109, and thus, both of them can be firmly joined to each other as illustrated in FIG. 5C.

Referring to FIGS. 2 and 4, the joint portions 201 a to 203 d are in an orthographic projection area of the LCD module 15 with respect to the bottom surface and are thus hidden thereunder, but the joint portions 201 d and 201 e are positioned outside the orthographic projection area of the LCD module 15. Therefore, even when the joint portions 201 d and 201 e are lap joined with the GFRP region 101 at the inside of the CFRP layer 105, there is no problem in mounting the LCD module 15.

Since the joining between the camera region 103 a and portions of the GFRP region 101 in the vicinity of the sidewalls 13 a can be carried out by lap joining, it is possible to secure the strength of the camera region 103 a. Moreover, by applying butt joining to the camera region 103 a having increased strength, it is possible to secure the strength of the antenna regions 101 a and 101 b. In the joint portions 201 a to 201 c, butt joining is carried out, thus providing a flat mounting surface for the LCD module 15 to the bottom surface. Moreover, the outer surface of the display casing 13 is coated with paint so that the joint portions 201 a to 201 e are invisible from the outside.

While the present invention has been shown and described by way of particular preferred embodiments in conjunction with the drawings, the present invention is not limited to the disclosed embodiments. It is to be understood that the present invention may employ any configurations known in the art as long as they can attain the effects of the present invention, for example the present invention can be used in an electronic apparatus such as a portable computer or a mobile phone.

If not otherwise stated herein, it is to be assumed that all patents, patent applications, patent publications and other publications (including web-based publications) mentioned and/or cited herein are hereby fully incorporated by reference herein as if set forth fully in their entirety herein.

This disclosure has been presented for purposes of illustration and description but is not intended to be exhaustive or limiting. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments were chosen and described in order to explain principles and practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated. 

What is claimed is:
 1. A method, comprising: fixing a laminated panel, which has been cut into a predetermined shape, to a mold, said laminated panel having an expanded layer disposed between layers made of a conductive resin; injection of molding non-conducting resin into the mold in which the laminated panel has been fixed; wherein a non-conductive region and a conductive region are joined to form a bottom surface of a display casing, said display casing having an inner and outer surface; and wherein an antenna mounting space is formed in the non-conductive region.
 2. The method according to claim 1, wherein the conductive resin comprises a carbon fiber reinforced plastic.
 3. The method according to claim 1, wherein the non-conductive resin comprises a glass fiber reinforced plastic.
 4. The method according to claim 1, wherein the conductive and non-conductive regions are butt jointed to form the bottom surface area.
 5. The method according to claim 1, wherein the conductive and non-conductive regions are lap jointed to form the bottom surface area.
 6. The method according to claim 1, wherein the non-conductive resin partially comes into the expanded layer causing them to become firmly joined to each other.
 7. The method according to claim 1, wherein the thickness of the antenna mounting space is made to be smaller than the thickness of the joint portions and the conductive resin region.
 8. The method according to claim 1, wherein the conductive region includes a camera region for mounting a camera.
 9. The method according to claim 1, wherein the outer surface of the display casing is coated with paint so that the joint portions are invisible from the outside.
 10. A method comprising: fixing a laminated panel, which has been cut into a predetermined shape, to a mold, said laminated panel having an expanded layer disposed between layers made of carbon fiber reinforced plastic; and injection molding glass fiber reinforced plastic into the mold in which the laminated panel has been fixed; wherein a glass fiber reinforced plastic region and a carbon fiber reinforced plastic region are butt joined to form a bottom surface of a display casing; and wherein an antenna mounting space is formed in the glass fiber reinforced plastic region. 